TCVN 8636: 2011

Contents
Foreword

Page
4

1. Application Scope......
2. Terms and definitions....
3. General Technical Requirements..
4. Penstock Materials
5. Load and Calculating Combination for exposed penstock..

5
5
7
11
12

6. Calculations for endurance and stableness of penstock...

15

7. Penstock Manufacturing...

19

8. Test of penstock..

21

9. Protected-painting for penstocks..

22

10. Monitoring system of penstocks

22

Appendix A (Regulation): Determining forces impacting onto penstock and its abutments
(Ai Values)

23

Appendix B (Regulation): Factors used in design calculation

26

Appendix C (Regulation): Standard diameter and minimum tolerant structural thickness of

pipe wall

28

Appendix D (Regulation): Maximum distance of reinforcing rings

Appendix E (Reference): Calculating the endurance and stableness of steel penstocks and their
attachments
Appendix F (Regulation): Shape of welding seam and outside faults of welding seam levels I,

29

and II, III

40

Appendix G (Regulation): Fault tolerance when manufacturing, installing penstocks..

41

Appendix H (Reference): Diagrams of welding seam position......

43

Appendix I (Regulation): Minimum testing pressure value...

44

References...

45

30

Vietnam Standards
Best Solutions Application Company Limited (BestCom)
19, Alley 11, Byway 178, Tay Son, Dong Da, Ha Noi
Tel: 04 66 73 78 74/0928 383 384/0928 383 484
Fax: 04 353 77 124. Email: Info@tieuchuan.vn
Web: www.tieuchuan.vn /
www/bestcom.vn

TCVN 8636:2011

Foreword
TCVN 8636:2011 Hydraulic Structures Steel Penstock Technical Requirements for designing,
manufacturing and installation, are converted since 32 TCN E5-74, regulated at Item 1, Clause 69 of
the Law on Standard and Technical Regulations and Point a, Item 1, Clause 7 of Decree No.
127/2007/N-CP on August 01, 2007 by the Government detailing the implementation of some
clauses of the Law on Standard and Technical Regulations.
TCVN 8636:2011 was compiled by the Center for Science and Technical Implementation of Irrigation
directly under University of Water Resources, proposed by Ministry of Agriculture and Rural
Development, assessed by Directorate for Standards, Metrology, and Quality, announced by Ministry
of Science and Technology.

NATIONAL STANDARDS

TCVN 8636:2011

Hydraulic Structures Steel Penstock Technical Requirements for designing, manufacturing

and installation

Application Scope

1.1 This standard regulates the technical requirements for designing, manufacturing, installation, and
testing steel penstocks located in the open-air in hydraulic, hydroelectric structures, including the
works of new manufacturing, repairing, restoring or upgrading.
1.2 This standard is not applied for penstocks underground or having steel cover of pressure tunnels of
hydraulic or hydroelectric structures.

1.3 When researching, designing, manufacturing, installing, besides the requirements of this standard,
it is necessary to obey the requirements of the related current standards.
2

Terms and definition

This standard uses the terms and definitions as follows:

2.1
Penstock
It is the pipe with inner water pressure impacting on throughout the length of the pipe.
2.2
Exposed penstock
It is the steel penstock exposed in the open-air.
2.3
Branch pipe
It is the steel penstock part at the branch pipe.

TCVN 8636:2011
2.4
Anchor
The anchor is used to support and fix the pipe to the spot, to ensure the steel pipe section not to move,
tilt, upturn or twist.
2.5
Support
The support is used to bear the weight of the pipe between the anchors, allowing the pipe to move
freely along pipe axis.
2.6
Water hammer
It is the phenomenon when water pressure in the pipe suddenly increases (positive water hammer) or
suddenly decreases (negative water hammer) occurring when the speed of water flow in the pipe
suddenly changes.
2.7
Membranous stress
Tensile stress or compressive stress evenly distributes along the thickness of the steel pipe and
shearing stress at the surface of the pipe wall.
2.8
Concentrated stress
The concentrated membranous stress and concentrated bending stress are not even in the thickness of
pipe wall.
2.9
Reinforced ring
It is the steel ring that is laid outside the pipe to reinforce the pressure endurance of the pipe in the
manufacturing, installing, operating, and exploiting process.
2.10
Supporting ring
The supporting ring is for reinforcing, increasing pressure endurance between the steel pipe and the
support.
2.11
Front-end ring block
The ring block is set at the beginning part of the steel pipe (or pipe cover) to block water.
2.12
Fixing collar

TCVN 8636:2011
The collar is set outside the steel pipe cover to prevent the pipe moving along its axis.
2.13
Cushion
It is the material with the deformation modulus less than the deformation modulus of steel. It is set
between the outside of the steel pipe cover and the concrete.
2.14
Compensator
It is the joint between two concentric steel pipes with function of adjusting the pipe length in order to
exclude differences by manufacturing, installing or by being sunk of work foundation and thermal
expansion when the pipe is fixed at two ends.
2.15
Leaking preventing material
It is the material used to prevent water leaking at compensator and checking holes on the pipe line.
2.16
Steel pipe roundness tolerance
It is the different value of two diameters that are perpendicular together at the same area of the steel
pipe.
2.17
Pipe spare thickness
It is the thickness part of the steel pipe that is probably rusted, worn out... in the working process,
andit is added into the calculated pipe wall thickness.
2.18
High water pressure test
It is the measure to fill water into the pipe line and increase the pressure to test the design quality,
manufactured material, and manufacturing, installing quality... to exclude excessive wilding stress
parts, shortcoming parts, to ensure the safe operation of the pipe.
3
General technical requirements
3.1
Do not make vacuums in pipe line in the operating process. When designing, installing the pipe
line, some solutions can be applied as follows:
a/ To put air vent pipes or valves to supplement air at pipe line ends or at the positions that can exist
vacuum when the pipe line is drained out or when the water flow passing the hydraulic machine
suddenly rises. The areas of air pipe holes or valves, F, m2, are determined by the formula (1):

TCVN 8636:2011
Q
400 C 10 p

where:
Q is air flow passing a hole, equal to maximum water flow passing the pipe line, m3/s;
C is flow coefficient, having the values as follows:
For valve: C = 0.5;
For air vent pipe: C = 0.7
p is pressure difference between the inner and the outer parts of the pipe line, MPa:
2E
p =

K Do

D0
K

is elastic modulus of steel, E = 0.21 106 MPa;

is thickness of pipe wall, cm;
is inner diameter of pipe line, cm;
is spare factor, with values as follows:
For exposed penstock: k = 10;
For concrete-covered penstock: k = 5;

b/ Select the the pipe line that the highest point of pipe line must be lower than the negative water
hammer (-), no less than 2.0m.
3.2 At the positions of the center axis of pipe line having any changes in one or two directions, they
must be fixed by anchors. If the distances between anchors are higher than the allowable distance of
L, it is considerable to adjust the pipe line or to lay more anchors appropriately.
3.3 Anchor design needs to consider two plans:
a/ Firmly fix the pipe line into the reinforce concrete block by the whole circumference of the pipe
(tight join);
b/ Tightly anchor the pipe by joint rings welded into anchor frames, the lower part is fixed in the
reinforce concrete (open join).
3.4 The pipe line part from anchor to anchor must be laid on intermediate supports. Intermediate
supports must allow the pipe line to shift when the environment temperature changes.
3.5 Depending on the inner diameter D0 of pipe line, select the type of intermediate supports as
follows:
D0 800mm: can use saddle support type or lateral slide type;
800mm < D0 <2000 mm: can use lateral slide type or roller type;
D0 >2000mm: only can use roller type.
8

TCVN 8636:2011
3.6 Supporting the pipe line must implement by rings that is firmly welded with the pipe line, to
transfer the load down to the support through the sliding sides or rollers.
3.7 Compensators must ensure tightness and easy elasticity of pipe line by pipe axis line. In case pipe
line is located in the soft ground, compensators must ensure to be elastic by the axis line and rotation
angle.
3.8 In the whole line of the pipe, it must ensure to drain out the water in the pipe line as well as the
groundwater, surface water in the corridor keeping the pipe line. There must be a convenient path for
monitoring, maintaining, and repairing the pipe line when necessary.
3.9 At the pipe line end, there must be a sluice-gate or emergency valve. These valves run
automatically under the impact of the maximum protection device if pipe line is broken, and under the
special protection device resisting the flow difference in the pipe line. The time of full close of the
sluice-gate or emergency valve is no more than 2 minutes.
3.10 Along the pipe line, there must be checking gates to periodically check, repair the inner part of
the pipe; the distance between checking gates are no more than 200m, and the diameter of
checking gate is no less than 450mm.
3.11 The structure of intermediate supports must have the ability to prevent horizontal shift and to
adjust the height when installing. Parts such as slide surfaces, rollers must be covered to prevent rain,
sunlight destroying the lubricant.
3.12 The distance between anchors is determined by the terrain, geology conditions around the pipe
line and calculated results for stress, deformation of pile line under the environment temperature effect
changing in the calculating combination. For pipe line section, the length of the section between two
anchors L0 with a compensator must meet the following condition by formula (2)
Et D A1+A4+A5+A6+A7+A8 (2)
where:

is coefficient of linear expansion of steel sheet: = 0.1210-4, 1/oC;

E
is elastic modulus of steel: E = 0.21x106 MPa;
t
is changing value of environment temperature, oC;
D
is average diameter value of pipe line, cm;

is thickness of pipe wall, cm;

A1, A4, A5, A6, A7, A8 are forces impacting on the pipe, determined by Appendix A.
3.13 The minimum length of pipe line section fixed in the anchor concrete is determined by operating
conditions of concrete under the impact of major loads caused by the pipe line in according to the
calculating combination.

TCVN 8636:2011
3.14 Anchors, intermediate supports must ensure the stability in sliding and stability of shrinkage for
most unfavorable calculated load combinations impacted by pipe line. If the anchor is shared by some
pipe lines, it must be calculated to control the case of non-synchronous operation of pipe lines.
3.15 The distance between intermediate supports L k, cm, is selected from the calculated result for
power and deflection of pipe line, combining with terrain, geology conditions of the pipe line. At first,
the distance between intermediate supports can be selected by the formula (3):
Lk 2.7 r

R'
q

where:
R
is tolerant decrease in tensile strength of the material, MPa, R from 15% to 20%;
q
is the evenly distributed load, including the weight of the steel pipe line and the full water load
in the pipe, MPa;
r,
is the inner radius and pipe-wall thickness, cm;
3.16 The calculation of the hydraulic loss h tt including the loss of friction along the pipe line h f and the
partial loss hc implemented for alignment plan and selected diameter. There must be a set-up of a
relating line between hydraulic losses and water flow passing the pipe line h tt = f (Q) to select a
reasonable plan.
3.17 There must be a calculation for pressure of maximum and minimum water hammer, a set-up
diagram of a pressure distributing line impacting the pipe wall along the length of pipe line. It is
carried out in two assumed modes that can occur when running a hydraulic unit of hydroelectric
station:
a/ Hydraulic units dismiss all additional loads;
b/ Hydraulic units increase additional loads from 0 to the norm additional load.
3.18 Water supplying plan for hydraulic units must be selected on the base of technical economic
standards, manufacture, transportation, installation conditions, and terrain, geology conditions of the
penstock line.
3.19 The optimal diameter of penstock is determined by formed specifications as follows:
a/ Water hammer pressure increases at the penstock line end:
- 25% to 30% for francis turbine (axis center turbine);
- 30% to 40% for kaplan turbine (propeller turbine);
- 10% to 15% for pelton turbine (wheel turbine);
b/ Cage revolutions are allowed to the norm revolution:
- 130% to 140% for turbine kaplan and francis hydraulic units;
- 105% to 110% for turbine pelton hydraulic unit.
10

TCVN 8636:2011
4 Penstock materials
4.1 Materials to make the steel pipe line including pipe cores, support rings, reinforced rings are hotrolled carbon steel, with the critical point from 230 MPa to 250 MPa, tensile strength limit from 380
MPa to 490 Mpa, relative elongation in the pentagonal sample from 23% to 26%; impact toughness in
the positive temperature from 7 kg.m/cm2 to 8 kg.m/cm2.
4.2 For the penstock with large diameter, bearing high pressure, with the product pD 60 MPa/cm,
to prevent pipe wall thickness too large, difficult to process, it is necessary to use low alloy steel with
the critical point from 300 Mpa to 400 MPa, or high strength steel with the critical point from 400
MPa to 600 MPa.
4.3 The selection of materials to process pipe line needs to be considered based on the design pressure
and their properties for strength, welding tolerance, conditions and the method of welding.
4.4 Materials of welding rod to weld penstock must be selected suitably with the welding steel.
Physical mechanic characteristics of welding seam must be equivalent to the basic steel, including:
a/ Critical point of welding seam, ch, MPa;
b/ Tensile strength limit of welding seam, , MPa;
c/ Bending angle in the cold condition, , degree (o);
d/ Relative elongation, , %.
4.5 Designed strength R of materials, MPa, is determined by the formula (4):
R= RTC C K m mv
(4)
Where:
RTC is the standard resistance of materials, determined as follows:
1/ For exposed penstock, it is equal to the critical point: RTC = ch;
2/ For underground penstock:
- When calculating with inner pressure, it is equal to the strength limit: RTC = ;
- When calculating with outside pressure, it is equal to the critical point: RTC = ch;
C
is a coefficient to change from main strength to standard strength, getting the value in
B.1 Table, Appendix B;
K
is factor of the consistency of materials, getting in B.2 Table, Appendix B;
m
is factor of operating condition. With exposed penstock, m is taken as follows:
- When penstock bears inner pressure: m = 0.71;
- When penstock bears outside pressure, m = 0.85;
- When penstock bears a special load, m = 0.95;
mv
is factor depending on the level of the work:
- For the work of the special level: mv = 0.80
11

TCVN 8636:2011
- For the work of level I:
mv = 0.85;
- For the work of level II:
mv = 0.95;
- For the work of level III: mv = 1.00.
4.6 In all cases, the stress calculated does not exceed the allowable stress. At the branching positions
and special danger sections of the pipe, the designed stress does not exceed 85% of allowable stress.
4.7 Other structures of the pipe line such as reinforced rings, anchor rings, support and other parts,
etc., the designed stress when bearing load including at the same time the major load, additional and
special load, does not exceed 90% of the critical stress ch of the materials.
4.8 Leak-proof materials at the compensator, checked gate usually use rubber washer. When water
pressure is from 8 MPa and over, leak proof material made from copper must be used.
5. Load and calculating combination of the exposed penstock
5.1 Load that impacts on the pipe line
5.1.1 When calculating, designing penstock of hydraulic and hydroelectric structures must include the
loads as follows:
a/ Main load includes:
1/ Water pressure impacting on the pipe wall is the sum of hydrostatic pressure and water pressure
that maximally increases when the hydraulic unit drains out additional load and spare coefficient K
taken from 1.1 to 1.5. Hydroelectric structures with water tower in the front pipe line must include
the overflowing water in the tower;
2/ Force along pipe line axis caused by the change of pipe diameter at bending elbows and
cushions of the compensator;
3/ Penstock weight includes the steel structure part and full water in the pipe;
4/ Friction between the steel pipe line and intermediate support, between water and the pipe wall,
and inner friction of the compensator;
5/ Centrifugal force by water flow to the bending elbows;
6/ Force of deformation caused by the environment temperature effect and inner water pressure for
the non-section pipe line;
7/ Pressure of gravelly soil in the anchors, supports;
8/ Force impact caused by the irregular shrinkage of anchors, supports;
9/ The pressure of gravelly soil impacts on parts of the underground pipe;
b/ Additional load includes:
1/ Vacuums exist in the pipe line when water is drained out;

12

TCVN 8636:2011
2/ The impact of force causing instability when there is half of water amount for pipes with
diameter > 2,400mm, pipe wall thickness <14mm, slant angle of pipe axis <15o;
3/ Load of wind;
4/ Load when testing hydraulic force;
5/ Load arising in the working process of concrete part;
c/ Special load includes the load by earthquake effect and other geological factors.
5.1.2 Calculated formulas to determine values of forces impacting on pipe line, anchors, and
intermediate supports, getting in Table A.1, Appendix A.
5.1.3 All forces of pipe line impacting on an anchor are analyzed by three combined components: by
pipe axis, by vertical direction and by horizontal direction. Based on those, all force components are
determined for the above and below sections of an anchor.
5.1.4 Friction coefficient f is selected as follows:
a/ In the compensator with the filling substances made by graphite wires or rubber rings: f =
0.3;
b/ At the intermediate support:
- For roller support, regularly lubricating:
f = 0.1;
- For side-sliding support, regularly lubricating:
f = 0.3;
- For side-sliding support, non-regularly lubricating:
f = 0.5.
5.1.5 The calculation of pipe line, and pipe components as well as hydraulic structures of building
parts, anchors, intermediate supports are implemented on the base of the combination of designed
loads. When designing, it is necessary to select the most unfavorable case that can occur in the
practical work.
5.2 Calculating combination for pipe line
5.2.1 The first basic combination includes the loads as follows:
a/ Maximum water pressure in the pipe is equal to hydrostatic pressure in proportion of maximum
water level of a storage tank and to maximum increasing water hammer pressure when the adjustable
mechanism of hydraulic turbine normally operates;
b/ Centrifugal force at bending pipe sections caused by water passing;
c/ The weight of pipe structure and of inside water;
d/ Water pressure impacting on bending pipe sections;
e/ Friction force at supports, compensators when the environment temperature changes;
f/ Friction force between water and pipe wall;
g/ Water pressure impacting on pipe sections with changing diameter;
13

TCVN 8636:2011
h/ Non-sectioned pipe force impacting on anchors, supports when the environment temperature
changes.
5.2.2 The second basic combination includes loads as follows:
a/ Outside air pressure when the inner pressure of the pipe decreases by normal regulated process of
the turbine;
b/ Weight of the penstock steel structure unit;
c/ Friction force at intermediate supports when pipe line is drained out of water and friction force at
the compensator when the environment temperature changes;
d/ Force produced by the elasticity of pipe line under the effect of changing environment temperature
for non-sectioned pipe line when there is no water inside the pipe.
5.2.3 The first operating combination includes loads as follows:
a/ Water pressure inside the pipe is equal to the sum of hydrostatic pressure in proportion of reinforced
water level of the storage tank and to maximum increasing water hammer pressure when hydraulic
unit drains out of the whole of additional loads. In case there is water tower, the overflow water in the
tower must be considered;
b/ Other loads impacting at the same time taken by the 1st basic combination, regulated at 5.2.1.
5.2.4 The second operating combination includes loads as follows:
a/ Air pressure outside the pipe , and inside the pipe occurs vacuum when the pipe line is drained out
of water but the ventilator at the pipe end is blocked;
b/ Other loads impacting at the same time taken by the 2nd basic combination, regulated at 5.2.2.
5.2.5 The third operating combination includes loads as follows:
a/ Air pressure outside the pipe , and inside the pipe occurs vacuum and there is negative water
hammer because the adjusting mechanism fails;
b/ Other loads are taken by the 2nd basic combination, regulated at 5.2.2.
5.2.6 The fourth operating combination includes loads as follows:
a/ The load is produced by earthquake;
b/ Other loads are gotten by the 1st basic combination, regulating at 5.2.1.
5.2.7 The combination of building period includes loads as follows:
a/ Weight of penstock steel structure unit;
b/ The friction force at intermediate supports, compensators for the sectioned pipe;
c/ Force produced by elasticity of pipe under the effect of changing environment temperature for nonsectioned pipe;
d/ Concrete load in the working phase impacting on closed anchor sections.

14

TCVN 8636:2011
5.2.8 Hydraulic testing combination includes loads as follows:
a/ Hydrostatic pressure inside the pipe when water is pumped to test;
b/ Weight of pipe steel structure and full water inside the pipe;
c/ Friction force at intermediate supports, compensators for sectioned pipe;
d/ Force produced by the elasticity of pipe when the environment temperature changes for nonsectioned pipe;
e/ Overload factors when calculating the pipe line, anchors, intermediate supports, taken in Table B.3,
Appendix B.
6. Calculation for strength and stability of penstock
6.1 All penstocks of hydraulic, hydroelectric structures when newly designed recovered, or repaired
must be calculated, checked for strength and stability in according to loads and the most unfavorable
calculated combination regulated in the Clause 6.
6.2 Standard diameter, minimum allowable structural thickness of pipe wall taken in Appendix C.
6.3 The calculation for strength and stability of pipe wall at the most dangerous areas includes:
a/ The main areas between spans of an anchor to the next no.1 intermediate support of two
successive intermediate supports;
b/ Areas at rings of an intermediate support;
c/ Areas at a reinforced ring;
d/ Areas at rings of an anchor.
6.4 The strength limit state of pipe wall at areas regulated at 6.3 is checked by changing stress td in 3rd
strength theory and maximum stress theory; see formulas (5) and (6):
td x2 z2 x z 3 xz2 R

x R

(6)

z R

where:
x

is axial stress in the pipe wall, MPa;

is inner circumferential stress in the pipe wall, MPa;

xz

is tangential stress impacting in the XZ plane, MPa;

is designed strength of materials, MPa.

6.5 For other basic details of pipe line, the strength limit state is checked by t R, where t is
calculated stress (normal stress or tangential stress).
15

TCVN 8636:2011
6.6 Designing penstocks of hydraulic, hydroelectric structures with inner diameter < 2400 mm, pipe
wall thickness < 14mm and the slant angle of pipe center axis to horizontal < 15o must be calculated,
checked for the strength and stability of pipe wall at areas regulated at item a and b of 6.3
6.7 For exposed penstock bearing the outside pressure of air pressure when value ro/ 66 (ro is pipe
radius and is pipe wall thickness), there must be reinforced rings for pipe wall to prevent the pipe
wall suppressed when inside the pipe occurs vacuum. The maximum distance of rings is regulated in
Appendix D.
6.8 When selecting reinforced rings, pipe wall needs to be checked the stability by the following
conditions, see formula (7):
2 m 6 kpz

where:
z

is pipe wall stress, MPa: z = PH r/;

PH

is air pressure: PH=0.1 MPa;

is the outer radius of pipe, cm;

is the thickness of pipe wall, cm;

is design coefficient: m = 0.75;

kpz

is critical stress with the critical pressure, MPa, determined as follows:

- When l/r 20: kpz = 0.17E
r

- When 0.5 l/r 10: kpz = 0.55E

;
r

- When 10 < l/r <20: allowing the interpolation of linear value kpz ;
If the calculated result is kpz > 0.5 , add adjusting coefficient taken inTable B.4, Appendix B;

is gross circumferential stress, MPa;

is distance between reinforced rings;

is elastic modulus of steel of pipe, MPa.

6.9 For non-sectioned penstock, check stability by formula (8)

x
z

m
kpx x kpz

(8)

16

TCVN 8636:2011
where:
m

= 0.9

is stress compressing along the axis of pipe wall, MPa;

is pipe wall stress, MPa:

is adjustable coefficient for critical stress, determined by 6.8;

kpz

is critical stress in proportion of critical pressure, MPa: kpz = C

C*

is adjustable coefficient depending on the ratio r/ . Value C* taken in Table 1:

z = PH x r/;

E /r.

Table 1
r/

C*

50

0.30

100

0.22

200

0.18

300

0.16

6.10 For pipe parts with changing diameter (conical shape), check stability by formula (9)

N
z m
N kp kpz

(9)

Where:
n

is total of axial forces: N =

A
i l

N kp
r* =

= 2

r*

kpx

cos2

0.9 r1 0.1 r2
cos

kpx, kpz, z taken by r*

m factor equal to 0.495

17

TCVN 8636:2011

Figure 1 Diagram of pipe parts with conical shape

6.11 Checking the stability of reinforced rings by formula (10) or formula (11):

nPH
f 0 y max
r l 0

m
Fk

n..PH

Rk2 J 1

m
..Pkp

RH C
k

(10)

n PH
Pkp
m

(11)

Where:
m

= 0.67;

= 1.10;

= 1.10 to 1.20;

PH

is outer pressure, MPa;

RH

is critical stress of materials, MPa;

stress coefficient, selecting as follows:

- When calculating by normal stress: C = 1.0;
- When calculating by tangential stress: C = 0.5;

r;

fo

= 0.003

is average radius of pipe line, cm;

y max

is maximum distance from the gravity center of the reinforced ring to its farthest point,

is length, cm:

cm;
l = 1.56

r a

is pipe wall thickness, cm;

is the width of ring contacting with pipe line, cm;

18

TCVN 8636:2011
Fk, Jk, Rk are the area, inertial moment and the radius crossing the gravity center of a reinforced
ring including the participation of pipe wall by length l;
Pkp = 3
J=
l

E J

Jk
1

3
Rk ..l 12 (1 2 ) r

is distance between the reinforced rings, cm;

is Poisson coefficient: = 0.3.

6.12 Checking the stability of pipe parts located in the concrete block that bears water infiltration
pressure or pressure when working on concrete by the following formula (12):
m mc Pkp n PH
where:
n
is overload factor: n = 1.2;
mc
= 0.8;
m
= 0.75;
Adjustable coefficient taken in Table B.4, Appendix B.
6.13 The calculation of strength and stability of steel pipe line and its accessories is referred in the
Appendix E.
7 Manufacturing of penstock
7.1 Exposed steel penstocks in the hydraulic, hydroelectric structures must be sectionally
manufactured and connected by compensators.
7.2 Each of straight pipe part between two anchors must be set on supports and must have a
compensator.
7.3 For sectional pipe lines with changing diameter, the transition part from one diameter to another
must be implemented by a conical pipe, with the minimum length to ensure the conical angle being no
more than 7o.
7.4 When changing the pipe wall thickness, the outer diameter of pipe line at the changed part must be
preserved. The transition from one kind of thickness to another must be continuously incremented by
each step from 1mm to 2mm.
7.5 Selected pipe wall thickness must be increased in comparison with the design thickness by
regulation as follows:
a/ Increasing 1mm for pipe lines that have not been eroded by alluvium and destroyed by
organisms in water;

19

TCVN 8636:2011
b/ Increasing from 2mm to 3mm for pipe lines have erosion from alluvium and destruction
from organisms in water;
7.6 Grading welding seams for pipe line by the below regulations:
a/ All of vertical welds of penstock must be Grade-I welds;
b/ Horizontal welds for works of from Class II to special class are Grade-I welds, for class III
and IV works are grade-II welds. Welds at the reinforced rings, rings of anchors, intermediate
supports, compensators at checking gate are grade-II welds. The remainders are grade-III welds;
c/ Quality of welds (grade I, II, III) are regulated in the Table F.1, Appendix F;
7.7 Inspecting weld quality must obey the current standards. The task for weld quality inspection is
regulated as follows:
a/ For Grade-I weld:
1/ Ultrasound: inspecting 100% of weld length;
2/ X-ray:
- No less than 25% of weld length and no less than 480mm;
- Inspecting 100% of the intersection of vertical welds and horizontal welds;
b/ For Grade-II welds:
- Ultrasound: inspecting 100% of weld length;
- X-ray: inspecting no less than 10% of weld length and no less than 240mm.
c/ Methods of inspection of welding defects by ultrasound must obey the current standard.
7.8 Allowable tolerance when manufacturing, installing steel penstock is regulated in the Table G.1,
Appendix G.
7.9 At positions that the penstock center axis changes by vertical and horizontal directions at the same
time, the pipe lines must be designed, manufactured by a bending elbow in the 3-dimension space.
7.10 Bending elbows are split to sections connected together by the central angle of curved radius. The
length of each section is no less than 300mm.
7.11 The curved radius of the bending elbow center is no less than 3 times of the inner diameter of the
elbow.
7.12 When designing for connected sections of pipe line, it is necessary to consider the sheet steel size
with regulations for position of vertical welds and horizontal welds to ensure that:
a/ For penstocks with large diameter, connected sections are made from many joined steel
sheets. The distance a by pipe circumference between vertical welds of the sheets put next together
is no less than 5 times of pipe wall thickness. See H.1, Appendix H;
20

TCVN 8636:2011
b/ The reinforced rings are welded far from the horizontal weld around the pipe circumference a
distance no less than 100mm;
c/ The vertical welds of joined pipe parts must be located in the stipulating areas I, II, III and IV. See
figure H2, Appendix H;
d/ The welds of the pipe column must be chamfered with a cut corner of 60 o, parts that emerge over
the inner surface of the pipe column are not higher than 3mm;
e/ The reinforced rings must be located far from the horizontal weld of pipe column with a distance c.
See figure H.2, Appendix H and the condition c 0.6 ro .
8. The penstock test
8.1 The penstock test is pressure test of water inside the pipe or pipe hydraulic force test. The process
and the diagram of pipe hydraulic force test are established at the same time with the design plan.
8.2 The diagram of pipe hydraulic force test regulated by the design requirements includes two
categories:
- The sectional testing diagram;
- The overall testing diagram.
The selection of testing diagram needs to base on general arranging characteristics, the inner pressure
distribution of the whole alignment for the long pipe lines; if the inner pressure has great changes in
sections, it is necessary to select the sectional testing diagram.
8.3 The value of minimum testing pressure is applied following the regulation in Appendix I.
8.4 The value of static pressure Po of the pipe line, at, is determined by formula (13):
Po = 0.1 Homax
(13)
where:

= 9.81 t/m3;
Homax is the maximum static water column of the pipe line, m is determined by maximum
static water altitude at the pipe line end (Timax) and the altitude of the pipe line to the turbine
(t):
Homax = Timax -t
8.5 The preparation of test, documents and testing process are appropriately established following the
current standards for steel penstock test.
8.6 Branched pipe sections need the hydraulic force test in the manufactory. In case of large branched
pipe parts and high pressure bearing, it is necessary to test with models. The actual value for safety
factors of the collapse pressure is not less than 3.

21

TCVN 8636:2011
9 Protecting paint for penstock
9.1 The entire metal surfaces of the penstock and the components in the static working mode must be
painted to prevent erosion and rust when the pipe line is in operating process.
9.2 The surfaces of moving components such as the sliding part of elastic parts, rollers, the sliding side
of supports, etc., must be coated by lubricant to prevent rust and to lubricate.
9.3 The coating paint used for the inner wall of the pipe must endure collision, hardness, and shininess
when the flow speed is more than 10m/s mixed with grains, chemical components of water provided
by the planning office.
9.4 The coating paint for outside the pipe and penstock components must endure the temperature up to
80oC and the change of temperature 50oC without any cracks or blisters.
9.5 The materials of coating paint to protect the surface must have labels with the right type and
technical specifications in according to designing requirements. Before coating, pipe surface must be
cleaned following the regulations. Painting procedure and paint maintaining procedure must be
implemented according to the design regulations.
10 The monitoring system of penstock
10.1 All penstock alignments of hydroelectric structures from grade III to special grade must have the
monitoring system to measure the shift by directions of anchors, supports and the transposition of the
pipe line.
10.2 The bench mark monitoring system includes the monitoring equipment and the monitoring bench
mark. The fixed monitoring equipment must be covered to prevent the impacts of rain, sunlight, and
the around environment. Monitoring bench mark must be made from stainless materials and must be
firmly located at favorable positions for the periodic measure and check.
10.3 The number of monitoring bench mark of penstock line is determined as follows:
a/ For the penstock with inner diameter D0 < 2m; each of the anchors and supports must be set a
monitoring bench mark. Each of the compensators is set a ruler to indicate the pipe elasticity. In case
of non-sectioned pipes between two contiguous anchors, set a monitoring bench mark fixed into the
penstock.
b/ For the penstock with inner diameter D0 > 2m; each of the anchors and supports must be set
with two monitoring bench marks by horizontal direction at two sides of pipe line. Each of the
compensators is set with two rulers to indicate the non-sectioned pipe elasticity. Between two
contiguous anchors, set a monitoring bench mark fixed into the penstock.
10.4 All monitoring bench marks of the monitoring system must be put into the general controlling
network of the work.
22

TCVN 8636:2011
Appendix A
(Regulation)
Determining the forces impacting on the pipe line and its anchors (Ai values)
Table A.1

Name of
force

Sign of force
Above part
Below part
Temperature conditions

Calculating formula

Anchor,
support

Pipe
wall

Anchor,
support

Increase
a/ Direction of action by vertical direction of the pipe:
1. The weight
A1 = gst Li sin
of pipe steel
structure
2. Water
D02
pressure
A2 =
Hi w
impacting on
4
test flange
3. Water

2
2
( D01
D02
) H i w
A 3=
pressure
4
impacting on
pipe part with
changing
diameter
4. Water
D02i
pressure
A4 =
H i w
impacting on
4
bending pipe
part
5. Water

( D12 D22 ) H i w
A5=
pressure
4
impacting on
cushion of
compensator
6. Friction
D02
force of water A6 =
H n w
on pipe wall
4
7. Friction
A7 = Dl bk M k H i w
force in
compensator
8. Friction
A8 = (gst+gw)Lkf cos
force at
support when
temperature
changes
9. Centrifugal
D02 V 2
force when
w
A9 =
4
g
the water
flows at
bending pipe
part
10. Force due A ' = F
2
0i
10
to horizontal
deformation

The parts included when calculating

Sectioned pipe
Continuous pipe

Decrease

Increase

Decrease

Pipe
wall

23

TCVN 8636:2011
11. Force due to
horizontal deformation
when pipe wall thickness
changes
12. Force due the change
of temperature
13. Force due the change
of temperature when pipe
wall thickness changes

''
10

Li zi
L
Fi
0i

'
A 11
= E F0 t

+
+

+
+

+
+

+
+

''
A 11
=

E t

L
L
F

l
l

0i

b/ Direction of action by normal direction

1. The components of pipe Qst = gst Lk cos
line steel structure
2. The components of the
Qw = gw Lk cos
weight of inner pipe water
c/ Direction of action by radius direction
Inner water pressure
P = H w
i

d/ Direction of action by vertical direction

1. The weight of pipe line GTP = gst Li
steel structure
2. The weight of inner
Gw = w FTP Li
pipe water
3. The weight of support
G P V on
4.The weight of anchor
G aP Va on
e/ Direction of action by horizontal direction
1. The horizontal
Tw = gw Li sin cos
components of the weight
of inner pipe water
2. Active pressure of soil
R (by standard)
Note 1: Units in the formulas in the table are as follows:
gst is the weight of steel structure for 1m-pipe line, t/m;
gst is the weight of water in 1m-pipe line, t/m;
D0, D01, D02 are inner diameters of pipe parts, m

Calculating the support

*
*

24

TCVN 8636:2011
D1, D2 is inner, outer diameter of compensator cushion, m;
is slant angle of pipe axis, degree;
w is unit mass of water, t/m3;
hw is water-column loss due to friction between water and pipe wall, m;
bk is the length of leaking preventing ring of compensator, m;
Mk is friction coefficient in the compensator: Mk = 0.3;
Lk is the distance between supports, m;
F is friction coefficient of the support;
V is water speed in the pipe; m/s;
is Poisson coefficient = 0.3;
z is circumferential stress due to inner pressure of pipe line, MPa;
F0i is area of horizontal section of steel pipe line, m2;
E is elastic modulus of steel: E = 0.21x106 MPa;
t is the value of the change of temperature, oC;
is elongation coefficient of steel = 0.12.10-4, l/degree;
Li is the length of pipe parts, m;
g is gravitational acceleration: g = 9.81m/s2;
Note 2:
a/ For axis vertical force and horizontal force having the sign (+) when impacting to rearward pipe
part by direction of the flow and the sign (-) when impacting to ahead force, see Figure B.1;
b/ With normal speed, A6 force not included;
c/ When small diameter A4 is calculated by the diameter and pressure at the central of pipe joining
elbow.

Figure A.1 Diagram determining the sign of the impacting force

25

TCVN 8636:2011
Appendix B
(Regulations)
The coefficients are used for the design calculation.
Table B.1- C coefficient changes from major strength to standard strength
The kind of materials
Carbon steel and low alloy steel

Metal at the butt welds

Metal at the fillet welds

Stress state

C coefficient

- Tensile, compress, bend

1.0

- Shear

0.6

- Bearing top side

1.5

- Bearing point contact

3.3

- Bearing line contact

2.2

- Bearing side by side contact

1.0

- Tensile, compress, bend

1.0

- Shear

0.6

- Tensile, compress, bend

0.7

- Shear

0.7

Table B.2 - K Coefficient including the consistency of materials

K coefficient for ch

K coefficient for

- When ch 240MPa

0.90

0.68

- When ch > 240MPa

0.85

0.64

Low alloy rolled steel

0.85

0.64

Head treatment rolled steel

0.80

0.60

Materials
Carbon steel:

Grade I weld

Similar to basic steel

Grade II weld

0.75

0.57

Grade III weld

0.65

0.50

26

TCVN 8636:2011
Table B.3 - The overload factor when calculating penstocks, anchors and supports
Name of Load

Overload coefficient

1. Hydrostatic pressure

1.0

2. Water hammer pressure

1.2

3. The weight of pipe steel structure

1.1

4. The weight of inner pipe water

1.0

5. The friction force at support

1.3

6. The friction force at compensator

1.2

7. Horizontal deformation

1.0

8. The load due to temperature

1.0

9. Outside air pressure, vacuum exists inside

1.2

10. The load due to irregularity shrinkage

1.1

11. The pressure due to infiltrating water from outside the pipe

1.2

12. The pressure when casting inserted concrete

1.2

13. The momentary load when transporting

1.2

14. Hydraulic testing pressure

1.0

15. The load due to earthquake

1.0

16. The load arises when installing

1.0

17. Outside air pressure when inside exists vacuum due to pipe
line drained out of water (air vent pipe fails)

1.0

Table B.4 Adjusted coefficient in case of KPZ > 0.5 T

KPZ/T

.KPZ/T

KPZ/T

.KPZ/T

KPZ/T

.KPZ/T

0.500

0.500

1.000

1.200

0.850

0.708

1.900

0.957

0.504

0.600

0.575

0.958

1.300

0.875

0.673

2.000

0.964

0.482

0.700

0.640

0.914

1.400

0.900

0.643

2.100

0.971

0.463

0.800

0.700

0.875

1.500

0.913

0.608

2.200

0.979

0.445

0.900

0.750

0.833

1.600

0.925

0.578

2.300

0.986

0.429

1.000

0.800

0.800

1.700

0.938

0.551

2.400

0.993

0.414

1.100

0.825

0.750

1.800

0.950

0.528

2.500

1.000

0.400

27

TCVN 8636:2011
Appendix C
(Regulations)
Standard diameter and allowable minimum structural thickness of pipe wall
Table C.1
Outer diameter
DH
(nominal)
Mm

Inner diameter
Do
(nominal)
mm

Minimum
thickness
mm

Outer diameter
DH
(nominal)
Mm

Inner diameter
Do
(nominal)
mm

Minimum
thickness
mm

620

600

4040

4000

10

720

700

4240

4200

12

820

800

4440

4400

12

920

900

4640

4600

12

1020

1000

4840

4800

12

1120

1100

5040

5000

12

1220

1200

5240

5200

12

1320

1300

5440

5400

12

1430

1400

5640

5600

12

1530

1500

5840

5800

12

1630

1600

10

6040

6000

12

1730

1700

10

6240

6200

14

1840

1800

10

6440

6400

14

1940

1900

10

6650

6600

14

2040

2000

10

6850

6800

14

2140

2100

10

7050

7000

14

2240

2200

10

7550

7500

14

2340

2300

10

8050

8000

14

2440

2400

10

9050

9000

14

2540

2500

10

9550

9500

14

2640

2600

10

10050

10000

14

2740

2700

10

10550

10500

16

2840

2800

10

11050

11000

16

2940

2900

10

11550

11500

16

3040

3000

10

12050

12000

16

3240

3200

10

12550

12500

16

3440

3400

10

13050

13000

16

3640

3600

10

13550

13550

16

3840

3800

10

14050

14000

16

28

TCVN 8636:2011
Appendix D
(Regulations)
Maximum distance between reinforced rings
Table D.1
Unit: m
Outer
diameter
m
1.02
1.53
2.04
2.54
3.04
3.64
4.04
4.64
5.04
5.64
6.04
6.65
7.05

6.0
3.0

10

6.0
4.0
3.6
2.7
1.8
1.8

12.6
6.0
5.4
4.5
3.0
3.0
2.0
2.0
2.0
1.8

12

14

Pipe wall thickness (mm)

16
18
20
22
24

26

28

30

32

10.8
7.2
6.0
4.5
4.5
4.0
3.6
2.0
2.0
2.0

20.0
12.0
8.0
7.2
6.0
5.4
5.0
4.5
3.6
3.0
3.0

18.0
12.0
9.0
8.0
7.2
7.2
5.4
5.4
4.0
4.0

16.5
15.5
14.0
12.6
12.6

18.0
16.5
14.4
14.4

20.0
18.0
16.5

20.0

16.5
12.0
10.8
8.0
8.0
7.5
7.5
6.0
5.4

16.0
12.6
10.8
10.0
9.0
9.0
8.0
8.0

20.0
14.0
12.6
10.8
10.0
9.0
9.0

18.0
14.0
14.0
12.0
10.8
10.8

29

TCVN 8636:2011
Appendix E
(References)
Calculating the strength, stability of steel penstock and accessories
E.1 Calculating the inside strength stress of steel penstock wall
E.1.1 At central section between the spans (Lk/2)
a/ Section circumferential normal stress component, zl, MPa, calculated by formula (E.1)
D

Do H p o cos cos
2

zl
2

In case:

Do
cos cos < 5%
2

z1 =

(E.1)

Hp, skip it:

Do H p
2

b/ Axial normal stress component (perpendicular to the section), x, MPa, determining by

formula (E.2)
x = x1 + x2

x =

(E.2)

Mu
Ai

Wo
Fo

c/ Radial normal stress component, MPa, determined by formula (E.3)

y = - Hp

(E.3)

in the formula (E.1), (E.2), (E.3):

is density of water: = 0.0001 MPa/cm;
Hp is calculated water column at section, cm;

is total of axial forces, hN;

is angle fixing the position on section, degree (o);

is axial slant, degree (o);
F0 is area of pipe section, cm2;
W0 is resisting moment of pipe: W0

Dtb2 ;
4

Dtb is average diameter of the section, cm;

TCVN 8636:2011
30

 is pipe wall thickness, cm;

Mu is bend moment at designed section, hN .cm;
- Central section at span: Mu =

q L2k
10

q L2k
8
q is the distributing load including the weight of pipe and inner pipe water, hN/cm;
Lk is span distance, cm.

- Central section at span with compensator: Mu =

E.1.2 At the section with the reinforced ring

a/ Circumferential normal stress component, zl, MPa, calculated by formula (E.1);
b/ Axial normal stress component (perpendicular to the section), x, MPa, determined by
formula (E.2)
c/ Radial normal stress component y, MPa, determined by formula (E.3)
d/ Concentrated stress component due to the ring by axial direction x3, MPa, determined by
formula (E.4)
x3 = 1.82 1 z1

(E.4)

where:
Mu is calculated at designed section position;
1 is flexibility coefficient of the ring, determined by formula (E.5):

Fk' a
Fk' 1.56 ro

(E.5)

Fk is area of horizontal section of the ring not including participating pipe wall part,
cm2;
Do
;
2
a is contacting width between ring with pipe wall, taken by regulations in figure E.1:
The other signs follow the note in E.1.1

r0 is inner radius of pipe, cm: r0 =

Figure E.1 Diagram determining contacting width a between the ring and pipe wall
31

TCVN 8636:2011
E.1.3 At nearby section of the support ring
a/ Circumferential normal stress component, zl, MPa, calculated by formula (E.1);
b/ Axial normal stress component (perpendicular to the section), x, MPa, determined by
formula (E.2)
c/ Radial normal stress component, , MPa, determined by formula (E.3)
d/ Shearing stress component, xz, MPa, due to shearing force causing in xoz plane, determined
by formula (E.6)

xz

2 Q sin
Fo

(E.6)

where:
Q = q Lk, hN;
q is the distributing load, hN/m;
Lk is span length between supports, m;
F is area of pipe section, cm2;
is nominal angle on pipe section; see Figure E.2.

Figure E.2 Diagram determining the nominal angle on the pipe section
E.1.4 At inside section of the support ring
a/ Circumferential normal stress component due to reactive force of ring causing, MPa, determined by
formula (E.7)
z3

z4

Mk
Wk

(E.7)

Nk
Fk

b/ Axial normal stress component, MPa, determined by formula (E.8)

32

TCVN 8636:2011
x1

Mu
W 0

x 2 1.82 l x1

x3

(E.8)

Fo

c/ Radial normal stress component, MPa, determined by formula (E.9)

y = - Hp
(E.9)
d/ Shearing stress component, yz, MPa, due to shearing force Tk causing in yoz plane,
determined by formula (E.10)

yz

Tk S x
Jx a

(E.10)

In the formula from (E.7) to (E.10):

Fk is area of pipe section, cm2: Fk = Fk + xL0
Fk is area of horizontal section of the ring, not including participating pipe wall part, cm2;
L0 is length of force bearing participating pipe part, cm;
Lo a 1.56 ro
Wk is resisting moment of ring with the section Fk, calculated by central principal axes;
Mk is bending moment, hN cm and Nk is vertical force, hN, due to the load Q causing, with
the value changed by the positions on pipe circumference:
- At the position = 0o and = :

Mk=

Q Rk
2

Nk=

Q r b

0.75
Rk

0.07 0.43

b
Rk

At the position = /2 and = 3/2:

Qb
4
Q
Nk =
4

Mk=

Rk is radius of the circle crossing gravity center of ring section, cm;

r is outer radius of pipe line, cm;
b is distance determined by Figure E.3
TCVN 8636:2011
33

Figure E.3 The diagram of pipe cross-section at support ring position

Mu =

q L2k
10

Tk is the horizontal force, hN:

- At position = 0o and = : Tk = 0.0;
- At position = /2 and = 3/2: Tk =

Q r b

1.25 ..;
Rk

Sx is static moment of pipe wall cross-section at angle position, cm3:

2

Sx = 2x r tb xxsin;
Jx is inertia moment of pipe wall cross-section, cm4: Jx = xr 3tb x;
rtb is average radius of pipe wall, cm;
Other signs are shown in the notes of E.1.1, E.1.2, E.1.3.
E.2 Calculating, checking the stability of pipe wall when pipe line contains half of water volume
Checking the stability of pipe wall when pipe line contains half of water volume by formula (E.11)
and (E.12):
x max x

L2k

r
R

(E.11)

td x2 z2 x z R

x R

(E.12)

z R

where:
coefficient determined as follows:
- For the span central section: =
- For the support section: =

1
;
16

1
;
32

34

TCVN 8636:2011

N1 6M 1
2

N
6M
z = 2 2 2

x =

The values N1, M1, N2 and M2 depend on D/Lk and /r at the positions = 0 and = /2,
determined by Figure E.4
Other signs are shown in the note of E.1

a/: The Diagram determng the value N1

The Diagram determining the value M1

b/:
c/: The Diagram determining the value M2

d/: The Diagram determining the value N2

Figure E.4 - The Diagram determining the values N1, M1, N2, M2
35

TCVN 8636:2011
E.3 Calculating the design of branched pipe parts
E.3.1 The shape and structural requirements of branched pipe parts
E.3.1.1 The branched pipe part including the following shapes:
a/ Three-beam branched pipe (three-branch pipe); see figure E.5 (a,b,c);
b/ Branched pipe with inside reinforced crescent cog; see figure E.6
c/ One-side branched pipe; see figure a of E.7
d/ Non-beam branched pipe; see figure b of E.7;
e/ Spherical branched pipe; see figure c of E.7

Figure E.5 Three-branched pipe

Figure E.6 Branched pipe with inside reinforced crescent cog

Figure E.7 Other forms of branched pipe part

a/ One-side branched pipe
b/ Non-beam branched pipe
c/ Spherical branched pipe

36

TCVN 8636:2011
E.3.1.2 The branched pipe part need to be selected appropriately to overall arranging conditions of the
work to ensure the flow runs smoothly, the flow volume evenly distributes to the machine units,
hydraulic loss factor is at minimum, good for manufacturing and installing.
E.3.1.3 Design of branched pipe part must have angle not more than 12o, angle not more than 60o
and ratio R0/R limited as follows:
a/ Non-beam, symmetric Y-shape:
from 1.25 to 1.30;
b/ Non-beam, one-side branched pipe shape:
from 1.20 to 1.35;
c/ Non-beam, four-branch shape:
from 1.30 to 1.50;
d/ Spherical shape:
from 1.30 to 1.60.
E.3.2 Calculation to select structure
a/ Pipe wall thickness at main stress area determined by formulas as follow:
- For three-beam branched pipe, branched pipe with inside reinforced crescent cog:

K1 P R
1 cos

For spherical branched pipe:

K 1 P Ro
2 1

b/ Pipe wall thickness at concentrated stress area for three-beam branched pipe, branched pipe
with inside reinforced crescent cog:
K2 P R

2 cos
where:
P is water pressure, MPa;
R is inner radius of pipe, cm;
R0 is inner radius of the sphere envelope;
is welding coefficient. The value taken as follows:
- For butt weld at two sides: = 0.95;
- For butt weld at one side: = 0.90;
[]1 and []2 are designed strength of materials taken by regulation in Items 4.5 and 4.6;
K1 is shape factor of branched pipe part:
- For three-beam branched pipe and branched pipe with inside reinforced crescent cog:
K1 = 1.1;
- For non-beam branched pipe and spherical branched pipe: K1 = 1.2;
- For one-side branched pipe, K1 taken in the table E.1
37

TCVN 8636:2011
Table E.1 Factor K1 for one-side branched pipe
Angle

d/D
From 45o to 50o

From 50o to 55o

From 55o to 60o

0.5

1.4

1.35

1.2

0.6

1.5

1.45

1.4

0.7

1.5

Note:
d, D are average diameters at intersection of the axes of major pipe and branched pipe.
K2 is lateral stress concentrating factor. For three-beam branched pipe, K2 = 1.5 + 2.0;
for branched pipe with inside reinforced crescent cog and non-beam branched pipe (figure E.8), K2
depends on the ratio

and angle , (o), taken in Table E.2

Figure E.8
Table E.2 - Lateral stress concentrating factor, K2

r/
40

50

60

70

80

90

100

120

0.10

0.22

0.34

0.47

0.60

0.15

0.30

0.45

0.59

0.74

0.89

1.04

0.29

0.46

0.63

0.80

0.97

1.14

1.31

1.48

10

0.57

0.77

0.96

1.15

1.35

1.54

1.73

1.93

12

0.86

1.07

1.29

1.51

1.72

1.94

2.16

2.37

14

1.14

1.38

1.62

1.86

2.10

2.34

2.58

2.71

16

1.43

1.69

1.95

2.21

2.48

2.74

3.00

18

1.71

2.00

2.28

2.57

2.85

20

2.00

2.31

2.61

2.92

38

TCVN 8636:2011
c/ The above method of determining the pipe wall thickness can be the base to carry out more analyses
or tests to modify. For small and medium branched pipe that bear no high pressure, it is unnecessary to
modify;
d/ Calculating the reinforced details such as beam, crescent cog, cover plate is carried out on the
fundamental analysis of its structure from conditions of bearing pressure of inner water impacting onto
pipe wall. This is a complex material strength calculation that needs to solve by suitable methods of
estimated calculation.

39

TCVN 8636:2011
Appendix F
(Regulations)
The weld shape and outside defects of grade I, II, III welds
Table F.1
Name of defects

Defect draws
Grade I weld

Allowable defects
Grade II weld

1. Concaves
Unallowable

2. Individual defects
on the surface

5. The edge, big lump

of the weld
6. Height deviation of
the corner weld
compared with
designed size K
7. The vertical and
transversal cracks
(not thrusting outside)
at the weld, the
concave welds are not
thick, the welding
burns and separate
openings are
complete

h<0.05. not deeper

than 1mm. Total
length of the concave
25% weld length

An individual defect
has the diameter not
bigger than 1mm, the
number of defects is
not more than 3 per
25cm of the weld

An individual defect
has the diameter not
more than 1mm, the
number of defects is
no more than 6 per
25cm of the weld

An individual defect
has the diameter not
more than 2mm, the
number of defects is
not more than 8 per
25cm of the weld

Unallowable

The string of defects

with length l < 15mm
or a place gathered
the defects in an area
< 1cm2 on 25cm weld
part

The string of the

defects with length l
< 20mm or a place
gathered the defects
in an area < 2cm2 on
25cm weld part

d-e 0.1b not more

than 2mm

d-e 0.2b not more

than 4mm

3. The strings and

places gathered
defects on the surface

4. The width is
uneven along weld
length, b is designed
width, d and e are
maximum practical
width of the weld

Unallowable

Grade III weld

For manual welding

d-e 0.1b not more
than 2mm
For automatic welding
d-b 0.3b
b-e 0.2b
Unallowable

Unallowable

Unallowable

Unallowable

Unallowable

K1 K 0.1xK
K1 K 0.1xK

Unallowable

Note: Only allowing one of four defects Nos.1, 2,3 and 4 exists on the length of 25cm weld.

40

TCVN 8636:2011
Appendix G
(Regulations)
The standard for tolerance
Table G.1 Allowable tolerance when manufacturing, assembling the penstock.
Name of deviation due to manufacturing,
assembling
Average inner diameter deviation measured at the
end of each connecting pipe reinforcement part
Dtb
Lout
=
- C1 C 2
Dtb
Where:
- Lout is the practical length of outer
circumference of the circle at reinforcement 0 of
pipe end
- C1, C2 are pipe wall thickness at two opposite
points on the same diameter
The difference of average inner diameters of two
pipe parts connected together
Difference of the width of steel sheet at the same
pipe part
Local gap between inner edge of reinforced ring
with the outside of the gauge when checking by
gauge with the length of 1500mm
Deviation of the length li of pipe reinforcement
part along the generatrix
Difference of lengths at the generatrices of pipe
reinforcement part at the ends of two diameters
perpendicular together
Deviation of distance from reinforced ring to the
end of pipe part edge
Deviation of distance between reinforced rings
Deviation of the length L of details with
individual shapes (taper, bend, three-branch...)
Bevel m of the end of pipe part
Deviation of gap between the inside and the
outside of compensators
k
k1
Deviation of pipe center with central line of outer
pipe parts in range of two contiguous supports Lk
Center deviation of each pipe part:
- by plane
- by altitude
Central shift of roller in the support
Height deviation of roller bed plate of the support

Allowable tolerance

Slant deviation of roller bed plate of the support

0.3mm per 100mm long

3mm

1.5 mm + 0.0003. D0
2mm
2mm on the length not more than 200mm
(2mm + 0.0007 li)
0.0005 li, mm
20mm
30mm
(2mm + 0.0007 L)
2mm
0.1 K
0.2 K
0.0005 Lk, mm
5mm
5mm
3mm
5mm

41

TCVN 8636:2011
Table G.2 - Formula to calculate the values of standard tolerance under Vietnam Standard
TCVN 2244-99: IT=a i
Unit: micrometer
Nominal size
mm

Grade of standard tolerance

IT5

IT6

IT7

IT8

IT9

IT10

IT11

500

7i

10i

16i

25i

40i

64i

100i

From over 500 to 3150

7i

10i

16i

25i

40i

64i

100i

Nominal size
mm

Grade of standard tolerance

IT12

IT13

IT14

IT15

IT16

IT17

IT18

500

160i

250i

400i

640i

1000i

1600i

2500i

From over 500 to 3150

160i

250i

400i

640i

1000i

1600i

2500i

Table G.3 - Standard tolerance values under Vietnam Standard TCVN 2244-99:
Unit: mm
Nominal size
mm

Grade of standard tolerance

IT11

IT12

IT13

IT14 IT15

IT16

IT17

IT18

From 50 to 80

0.19

0.30

0.46

0.74

1.20

1.90

3.00

4.60

From 80 to 120

0.22

0.35

0.54

0.87

1.40

2.20

3.50

5.40

From 120 to 180

0.25

0.40

0.63

1.00

1.60

2.50

4.00

6.30

From 180 to 250

0.29

0.48

0.72

1.15

1.85

2.90

4.60

7.20

From 250 to 315

0.32

0.52

0.81

1.30

2.10

3.20

5.20

8.10

From 315 to 400

0.36

0.57

0.89

1.55

2.30

3.60

5.70

8.90

From 400 to 500

0.40

0.63

0.97

1.75

2.50

4.00

6.30

9.70

From 500 to 630

0.44

0.70

1.10

2.00

2.80

4.40

7.00

11.00

From 630 to 800

0.50

0.80

1.25

2.30

3.20

5.00

8.00

12.50

From 800 to 1000

0.56

0.90

1.40

2.60

3.60

5.60

9.00

14.00

From 1000 to 1250

0.66

1.05

1.65

3.10

4.20

6.60

10.50

16.50

From 1250 to 1600

0.78

1.25

1.95

3.70

5.00

7.80

12.50

16.50

From 1600 to 2000

0.92

1.50

2.30

4.40

6.00

9.20

15.00

23.00

From 2000 to 2500

1.10

1.75

2.80

5.40

7.00

11.00

17.50

28.00

From 2500 to 3150

0.19

2.10

3.30

0.74

8.60

13.50

21.00

33.00
42

TCVN 8636:2011
Appendix H
(References)
Diagram of weld positions

Figure H.1- Distance a of vertical welds

Vertical weld (ng hn dc)
Pipe central line (ng tm ng)

Note:
1. Vertical welds are in I, II, III, and IV sections;
2. Distance c is between horizontal welds and the ring.
Figure H.2 The positions of the vertical welds of joined pipe lines
Horizontal direction: (phng ngang)

43

TCVN 8636:2011
Appendix I
(Regulations)
Values of minimum testing pressure
Table I.1
Pressure value P
calculated by static
pressure P0 of pipe line
The value of maximum
positive water hammer
pressure, Pv
The value of designed
pressure of steel pipe line,
Ptt
The value of testing
pressure, Ptn

< 40

Range of water column in the hydroelectric station

From 40m to 100m
>100m

From 1.5 P0 to 1.7 P0

From 1.3 P0 to 1.5 P0

From 1.15 P0 to 1.3 P0

From 1.6 P0 to 1.8 P0

From 1.4 P0 to 1.6 P0

From 1.25 P0 to 1.4 P0

From 1.7 P0 to 1.9 P0

From 1.5 P0 to 1.7 P0

From 1.35 P0 to 1.5 P0

44

TCVN 8636:2011
References
1. TCVN 8298:2009: Hydraulic structure Manufacturing and installing mechanical equipment,
steel structure Technical requirements.
2. TCVN 2245-99: ISO System of tolerance and assembly. Basic of tolerance, deviation and
assembly
3. TCVN 4394: 1986: Non-destructive testing. Classification and evaluation of welds defects by
X-ray method
4. TCVN 4395: 1986: Non-destructive testing. Checking of metal weld by X-ray and gamma ray
5. TCVN 5400: 1991: The welds. General requirements of mechanical samples testing properties
6. TCVN 5401: 1991: The welds. Method for testing the bend
7. TCVN 5402: 1991: The welds. Method for testing the impact strength
8. TCVN 5403: 1991: The welds. Method for testing the tensile
9. TCXD 165: 1988: Non-destructive testing. Checking the weld quality of steel pipe by ultrasonic
method.
10 Technical standards for gates and penstocks Hydraulic gate and penstock association
Published in 1981.
11. N.V. Klingert, A.Kh. Moscow - 1973
12. S.I. Levin. Moscow 1970.

Translated from the original in Vietnamese

File No. 0237 (Nhuan/Linh)
Date: Feb. 29, 2012
Chief of Translation Section

Ho Chi Minh City Research and Translation Association

certifies the true signature of
Vice-Chief of Administrative Office

45